*575INSTBAG* 575INSTBAG 2009 14 F 150 4”/6” LIFT KIT · 2020-04-15 · 2Rr N3 Shocks (660751) 2Rear Blocks -9/16 x 3 x 11 Ubolts-9/16Bag 110MMSTUDBAG2-Strut Spacers 20165: 649052:

THANK YOU FOR CHOOSING ROUGH COUNTRY FOR YOUR SUSPENSION NEEDS.

Rough Country recommends a certified technician install this system. In addition to these instructions, professional knowledge of disassemble/reassembly procedures as well as post installation checks must be known. Attempts to install this system without this knowledge and expertise may jeopardize the integrity and/or operating safety of the vehicle.

Please read instructions before beginning installation. Check the kit hardware against the parts list. Be sure you have all needed parts and know where they go. Also please review tools needed list and make sure you have needed tools.

PRODUCT USE INFORMATION As a general rule, the taller a vehicle is, the easier it will roll. We strongly recommend, because of rollo-ver possibility that seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur.

Generally, braking performance and capability are decreased when larger/heavier tires and wheels are used. Take this into consideration while driving. Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height over the intended height of the Rough Country product purchased. Mixing component brands is not recommended.

Rough Country makes no claims regarding lifting devices and excludes any and all implied claims. We will not be re-sponsible for any product that is altered. If questions exist we will be happy to answer them concerning the design, func-tion, and correct use of our products.

The 6”suspension system was developed using a 35X12.50/18 tire with 18 x 9 wheel with 4 1/2” backspace. When using a stock wheel the maximum tire width is 11 1/2”. The lifts were designed to lift the front to level the vehicle. Due to man-ufacturing, dimension variances, and inflation all tire and wheel combinations should be tested prior to installation on all oversized / wider then stock tires We recommend a wheel not exceeding 8" in width be used with a minimum backspac-ing of 4.5" to a maximum of 5".

Some 2014 vehicles will require the EPAS (Electronic Power Assist Steering) plugs to be discon-nected prior to beginning installation of this kit. See installation instructions. Failure to disconnect these plugs may result in damage to the EPAS module resulting in an error message being displayed, which will require re-placement of the EPAS module

NOTICE TO DEALER AND VEHICLE OWNER Any vehicle equipped with any Rough Country product should have a “Warning to Driver” decal installed on the inside of the windshield or on the vehicle’s dash. The decal should act as a constant reminder for whoever is op-erating the vehicle of its unique handling characteristics.

2009-14 F-150 4”/6” LIFT KIT

921575000B

5mm Allen Wrench 8mm Allen Wrench 8mm wrench /socket 10mm wrench /socket 12mm Wrench 13mm wrench / socket 15mm wrench /socket 16mm wrench /socket 18mm wrench /socket 19mm wrench /socket 21mm wrench /socket 22mm wrench /socket 24mm wrench /socket 30mm wrench /socket

Tools Needed:

Floor Jack Jack stands Reciprocating Saw Hammer 9/16 wrench /socket 1 1/16” Wrench Drill 1/4” Drill Bit 5/8” Drill Bit 41/64” Drill Bit 11/32” Drill Bit

*575INSTBAG* 575INSTBAG

Torque Specs:

Size Grade 5 Grade 8 Size Class 8.8 Class 10.9 5/16” 15 ft/lbs 20ft/lbs 6MM 5ft/lbs 9ft/lbs 3/8” 30 ft/lbs 35ft/lbs 8MM 18ft/lbs 23ft/lbs 7/16” 45 ft/lbs 60ft/lbs 10MM 32ft/lbs 45ft/lbs 1/2” 65 ft/lbs 90ft/lbs 12MM 55ft/lbs 75ft/lbs 9/16” 95 ft/lbs 130ft/lbs 14MM 85ft/lbs 120ft/lbs 5/8” 135ft/lbs 175ft/lbs 16MM 130ft/lbs 165ft/lbs 3/4” 185ft/lbs 280ft/lbs 18MM 170ft/lbs 240ft/lbs

59930 (4” Kit w/ N3 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 555BOX3 555BOX1 20165 x 2 59931 (4” Kit w/ N3 Struts & N3 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 555BOX1 23018 20165 x 2 59970 (4” Kit w/ V2 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 555BOX3 555BOX1 760751 59971 (4” Kit w/ N3 Struts & V2 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 555BOX1 23018 760751 59830 (6” Kit w/ N3 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 557BOX1 557BOX3 59831 (6” Kit w/ N3 Struts & N3 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 557BOX1 649055 x 2 20165 x 2 59870 (6” Kit w/ V2 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 557BOX1 557BOX4 760751

57430 (4” Kit w/ N3 Rr Shocks): 575BOX1 1598BOX10 1558BOX1 1558BOX2 555BOX3 555BOX1 20165 x 2

57432 ((11-13 Only) 4” Kit w/ N3 Struts & N3 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 555BOX1 23018 20165 x 2

57431 ((2014 Only) 4” Kit w/ N3 Struts & N3 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 555BOX1 649051 x 2 20165 x 2 57470 (4” Kit w/ V2 Rr Shocks): 575BOX1 1598BOX10 1558BOX1 1558BOX2 555BOX3 555BOX1 760751

57472 ((11-13 Only) 4” Kit w/ N3 Struts & V2 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 555BOX1 23018 760751

57471 ((2014 Only) 4” Kit w/ N3 Struts & V2 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 555BOX1 649051 x 2 760751

Kit Boxes 2009-10 Models 2009-10 Models Cont’d

2011-14 Models (4” Kits)

59871 (6” Kit w/ N3 Struts & V2 Rr Shocks): 575BOX1 1598BOX10 1598BOX1 1598BOX5 649055 x 2 760751

57530 (6” Kit w/ N3 Rr Shocks): 575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 557BOX3

57532 ((11-13 Only) 6” Kit w/ N3 Struts & N3 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 649055 x 2 20165 x 2

57531 ((2014 Only) 6” Kit w/ N3 Struts & N3 Rr Shocks): 575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 649052 x 2 20165 x 2 57570 (6” Kit w/ V2 Rr Shocks): 575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 557BOX4 760751

57572 ((11-13 Only) 6” Kit N3 Struts & V2 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 649055 x 2 760751

57571 ((2014 Only) 6” Kit w/ N3 Struts & N3 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 649052 x 2 760751

57557 ((2014 Only) 6” Kit w/ Vertex Coilovers & V2 Rr Shocks):

575BOX1 1598BOX10 1558BOX1 1558BOX2 557BOX1 680004 680005 760751

Kit Boxes

2011-14 Models (6” Kits)

KIT CONTENTS

575INSTBAG: Instructions 2-Cable Ties 575Bag2: 8-Block Shims 2-Fr Brake Line Brackets 1-E-Brake Bracket 1557Bag15: For Pass Diff Brace 2-12mm-1.75 x 35mm Bolt 2-12mm-1.75 Lock Nut 4-1/2” Flat Washers 1598Bag1: For Fr Dr Side Upper Diff Mount: 1-9/16” x 4” Bolt 2-9/16” Flat Washers 1-9/16” Lock Nut

For Fr Dr Side Lower Diff Mount: 1-9/16” x 4” bolt 2-9/16” Flat Washers 1-9/16” Lock Nut For Rr / RrCross-Member: 2-18mm x 160mm Bolts 4-18mm Flat Washers 2-18mm Lock Nuts For Fr Drivers Side Diff Mount: 1-9/16” x 4 1/2’ Bolt 2-9/16” Flat Washers 1-9/16’” Lock Nut 1598Bag11: For Front Skid Plate: 4-3/8” x 1” Bolt 4-3/8” Flat Washers For Front Driveshaft: 6-10mm x 80mm Allen Bolts For Front Brake Line Bracket: 2-5/16” x 3/4” Bolt 4-5/16” Flat Washer 2-5/16” Lock Nut For Sway Bar Brackets: 4-3/8” x 1’ Bolts 8-3/8’ Flat Washers 4-Lock Nuts 1598Bag8 (Included in 1598Box1 & 5): For 2010 Models with 16mm Caliper bolts 4-5/16” thick washers 1500: For Front Lower Control Arms: 4-18mm x 160mm Cam Bolts 4-Flat Washers 4-18mm Lock Nuts

Kit Includes: 1558Box1 (11-14) or 1598Box1 (09-10): 1-Driver Side Knuckle 1-1598Bag8 (09-10 Models Only) 1558Box2 (11-14) or 1598Box5 (09-10): 1-Pass Side Knuckles 1-1598Bag8 (09-10 Models Only) 1598Box10: 1-Fr Cross-Member 1-Rr Cross-Member 575Box1: 1-1500 1-Rear Brake Bracket 1-575INSTBAG 1-1598Bag1 1-1598Bag11 1-1598Bag3 1-575Bag2 1557Bag15 2-Diff Drop Brackets 1-Diff Brace 1-Dr Sway Bar Drop Bracket 1-Pass Sway Bar Drop Bracket 1-Skid Plate 1-Driveshaft Spacer 557Box1 (6” Kits): 2-Rear Blocks 1-1263Bag2 4-9/16 x 3 x 13 Ubolts 1-9/16Bag 557Box3 (6” Kits): 1-10MMSTUDBAG-2 2-Strut Spacers 2-Rr N3 Shocks (660751) 555Box1 (4” Kits): 2-Rear Blocks 4-9/16 x 3 x 11 Ubolts 1-9/16Bag 555Box3 (4” Kits): 1-10MMSTUDBAG-2 2-Strut Spacers 20165: N3 Rear Shock 649052: 2014 6” N3 Loaded Strut 649055: 2009-13 6” N3 Loaded Strut 760751: 2-V2 Rear Shocks 680004: Dr Vertex Coilover 680005: Pass Vertex Coilover 690002: Rear Vertex Shock 23018: 2-2009-13 4” N3 Struts 649051: 2014 N3 Loaded Strut

10MMSTUDBAG-2: For Front Strut Spacers: 6-3/8” Self Clinch Studs 1-10mm Hex Nut 6-Flange Lock Nuts 1598Bag3: For Rear Brake Line Brkt: 1-3/8” x 1’ Bolt 2-3/8” Flat Washers 1-3/8” Lock Nut For Rear E-brake Bracket: 1-7/16” x 1” Bolt 2-7/16” Flat Washers 1-7/16” Lock Nut 1-5/16” x 3/4” Bolt 2-5/16” Flat Washers 1-5/16” Lock Nut 1263Bag2:

For Anti-Wrap Blocks: 4-7/16” x 3” U-Bolts 8-7/16” Nuts 8-7/16” Washers 9/16Bag: For Rear Ubolts: 8-9/16” Nuts 8-9/16” Washers

KIT CONTENTS

6” Kit Shown in Picture

INSTALLATION INSTRUCTIONS

1. Chock the rear wheels and jack up the front of the vehicle. 2. Place jack stands under the frame rails and lower onto jack stands. 3. Remove the wheels/tires using a 21mm socket. 4. On 2011 models and if equipped, remove the EPAS (Electronic Power Assist Steering) Plugs as shown located on

the steering assembly by the front differential. See Photo 1 & 2. This must be done BEFORE installation is start-ed.

5. Remove tie-rod end using a 21mm wrench. Using a hammer hit the side of the knuckle to pop tie-rod out. Photo 3. 6. Remove the ABS and brake line bracket from the knuckle using a 8mm wrench for the ABS wire and a 10mm

wrench for the brake line bracket. Retain hardware for reuse. See Photo 4.

7. Remove the vacuum line from the hub. See Photo 5. 8. Using a 19mm socket & 21mm wrench, remove brake caliper as shown in Photo 6. Hang caliper out of way. Do not

let caliper hang by brake hose as this will damage hose. Retain hardware for reuse. Remove rotor.

PHOTO 3

PHOTO 5 PHOTO 6

PHOTO 4

TAP TO LOOSEN THE TIE ROD REMOVE BRACKET FROM KNUCKLE

REMOVE VACUUM LINE FROM HUB REMOVE THE CALIPER FROM KNUCKLE

PHOTO 1 PHOTO 2

9. Remove the dust shield using a 8mm socket and dust cap. See Photo 7. 10. Remove the ABS wire from the bearing assembly using a 5mm allen wrench. See Photo 8.

11. Remove the axle nut using a 13mm socket. Retain hardware for reuse. See Photo 9. 12. Loosen the upper ball joint nut using a 21mm wrench. Tap lightly with a hammer to release ball joint from knuckle.

See Photo 10.

13. Loosen the lower ball joint using a 24mm wrench. Tap lightly with a hammer to release ball joint from knuckle. See Photo 11.

14. Remove the upper and lower ball joint nuts and remove the knuckle from the vehicle. **Note** Use caution when removing the CV axle from the knuckle. Damage to CV actuator seal will affect 4wd operation. 15. Using a 8mm wrench, remove the (3) bolts securing the actuator to the knuckle. See Photo 12.

16. Remove the sway bar links from the sway bar using a 19mm wrench. Retain hardware for reuse.

PHOTO 7

REMOVE THE DUST SHIELD

PHOTO 8

REMOVE THE ABS WIRE

PHOTO 9 PHOTO 10

PHOTO 11 PHOTO 12

REMOVE THE AXLE NUT TAP TO LOOSEN UPPER BALL JOINT

TAP TO LOOSEN LOWER BALL JOINT

17. Remove the lower strut nuts using a 18mm socket. See Photo 13. Retain hardware for reuse. 18. Remove the sway bar from the frame mount using a 15mm socket. Please note the position that the sway bar is in-

stalled from the factory to make sure it is reinstalled correctly. Retain hardware for reuse. See Photo 14.

19. Remove the lower control arm using a 21mm and 1-1/16” wrench. Retain hardware for reuse. See Photo 15. 20. Remove the strut from the upper mount using a 15mm socket / wrench. Retain hardware for reuse. See Photo 16.

21. Remove the lower skid plate by removing the 4 bolts using a 13mm socket. See Photo 17. 22. Remove the driveshaft from the front differential using a 10mm socket. See Photo 18. Secure driveshaft out of the

way.

PHOTO 13 PHOTO 14

REMOVE THE LOWER STRUT NUTS REMOVE THE SWAY BAR FROM FRAME

PHOTO 15 PHOTO 16

PHOTO 17 PHOTO 18

REMOVE THE LOWER CONTROL ARM REMOVE THE UPPER STRUT HARDWARE

REMOVE THE LOWER SKID PLATE REMOVE THE DRIVE SHAFT

23. Remove the stock rear cross-member using a 15mm & 18mm socket. Retain hardware for reuse. See Photo 19. 24. Tape supplied cutting template on front and back side of the driver side lower cross-member mount. Using template

as a guide, trim cross-member mount to allow the differential to be removed. See Photo 20.

25. Remove the differential vent tube from the differential. 26. Support the differential using a floor jack and remove the upper driver side differential bolt using a 18mm wrench.

Retain hardware for reuse. See Photo 21. 27. Remove the passenger side differential bolt using a 18 & 21mm wrench. Retain hardware for reuse. See Photo 22.

28. Remove the lower rear driver side differential bolt using a 21mm socket / wrench. Lower and remove the differential from the vehicle. See Photo 23.

29. Complete the trimming of the frame on the driver side using the template and drill a pilot hole in the center using 1/4” drill bit. Finish the hole shown in Photo 24 using a 5/8” drill bit.

PHOTO 19 PHOTO 20

PHOTO 21 PHOTO 22

PHOTO 23 PHOTO 24

REMOVE THE REAR CROSS-MEMBER INSTALL THE TEMPLATES AND CUT

REMOVE THE UPPER DRIVER DIFF BOLT REMOVE THE PASSENGER SIDE DIFF BOLT

REMOVE THE DR UPPER DIFF BOLT DRILL HOLE USING THE TEMPLATES

30. Install the upper differential drop bracket on the driver side using the stock hardware. See Photo 25. Do not tighten at this time.

31. Install the passenger differential bracket using the stock hardware. Photo 26. Do not tighten at this time.

32. Install the differential in the new brackets with the supplied hardware. Install the 9/16” x 4” bolt, washers & nut in the in the passenger side mount. See Photo 27.

33. Swing the differential up to the drive and install the 9/16” x 4” bolt, washers and nut from the front to rear. NOTE: The differential mounts will need to be loose to push the differential to the passenger side in order to clear the rack and pinion and install the bolt. See Photo 28.

34. Install the rear cross-member and sway bar mounts on the driver and passenger side as shown in Photo 29. The supplied 18mm x 160mm bolt will install through the sway bar bracket and rear cross-member, securing it to the stock location. Do not tighten at this time.

35. Install the passenger side differential brace as shown in Photo 30 using the supplied 12mm hardware in 1557BAG15. Do not tighten at this time.

PHOTO 25 PHOTO 26

INSTALL THE DR DIFF BRACKET INSTALL THE PASS DIFF BRACKET

PHOTO 27 PHOTO 28

PHOTO 29 PHOTO 30

INSTALL THE PASS DIFF IN THE BRACKET INSTALL THE DR DIFF IN BRACKET

INSTALL RR CROSSMEMBER /SWAY BAR BRKTS INSTALL THE PASS SIDE DIFF BRACE

INSTALL THE SKID PLATE

36. Install the supplied 9/16” x 4 1/2” rear differential bolt through the sway bar mount and new differential mount. See Photo 31. Do not tighten at this time.

37. Reinstall the stock sway bar flag bolts in the new sway bar drop bracket to keep the bracket aligned while tightening the cross-member bolts. See Photo 32.

38. At this time tighten all diff bolts using 18mm socket / wrench for the upper diff bolts and a 21mm & 22mm socket / wrench for the new supplied lower diff bolts. Also tighten the passenger side diff brace hardware using a 15mm & 18mm socket /wrench.

39. Reinstall the vent tube on the differential. 40. Install the front cross-member using the factory hardware. See Photo 33. Do not tighten at this time. 41. Install the lower control arms using the supplied 18mm x 160mm cam bolts, washers and nuts. See Photo 34.Do not

tighten at this time.

42. Install the new skid plate in the front and rear cross-members threaded holes using the supplied 3/8” x 1” bolts, washers. See Photo 35. Tighten using a 9/16” socket.

43. Tighten all upper cross-member bolts using a 21mm, 1 1/16” socket and 1 1/16” wrench. 44. Tighten the sway bar drop mounts to the frame using the factory hardware with a 15mm socket. See Photo 36.

PHOTO 31 PHOTO 32

PHOTO 34

PHOTO 35 PHOTO 36

INSTALL THE DR SIDE LOWER DIFF BOLT PLACE SWAY BAR HARDWARE IN BRACKET

INSTALL THE STOCK CONTROL ARMS

INSTALL THE SKID PLATE TIGHTEN THE SWAY BAR BRACKETS

PHOTO 33

INSTALL THE FRONT CROSS-MEMBER

45. Install the drive shaft spacer with supplied 10mm x 80mm hardware. See Photo 37. Tighten using a 8mm allen wrench.

46. Using a 10mm wrench remove the brake line bracket from the driver and pass side frame. See Photo 38.

47. On the passenger side remove the brake line from the two factory clips. See Photo 39. 48. Install the new brake line bracket on the driver and passenger side with the stock hardware. See Photo 40.

49. Install the factory passenger side brake line in the new bracket using the supplied 5/16’ x 3/4” bolt, washer and nuts. See Photo 41.

50. On the driver side, pull slightly on the brake line to allow the line to be installed on the new bracket. Secure the brake line to the new bracket with the supplied 5/16” x 3/4” bolt, washers and nut.

51. Using a 13mm socket / wrench, tighten the supplied brake line hardware and 10mm for the stock hardware.

52. If installing the Rough Country lifted struts or Vertex coilovers refer to the instructions included with the strut and skip to step 58.

53. Install the supplied 10mm studs in the strut spacers with a 17mm wrench. Use the supplied 10mm hex nut to pull

the studs into the spacer. Do not use an impact to install studs. See Photo 42.

PHOTO 37 PHOTO 38

INSTALL THE DRIVE SHAFT SPACER REMOVE THE BRAKE LINE BRACKET

PHOTO 39 PHOTO 40

PHOTO 42

REMOVE THE STEEL LINE FROM MOUNTS INSTALL THE BRAKE LINE BRACKET

INSTALL THE 10MM STUDS IN SPACER

PHOTO 41

REINSTALL THE BRAKE LINE TO BRACKET

54. Using the stock hardware, install the strut spacers on the struts. Tighten using a 15mm socket. See Photo 43. 55. Install the strut with strut spacers installed in the stock upper mount. Secure with supplied 10mm flange lock nuts.

See Photo 44. Do not tighten at this time.

56. Install the lower strut in the lower control arm using the factory hardware. Tighten using a 30mm and 1-1/16” wrench. 57. Tighten upper strut mount hardware using a 17mm wrench. 58. Install the sway bar body on the sway bar links located on the lower control arms. Install nut to hold the sway bar in

place but do not tighten at this time. See Photo 45. 59. Swing up the sway bar and install on the sway bar drop brackets using the supplied 3/8” x 1” bolts, washers and

nuts. Tighten using a 9/16” on the sway bar drop hardware and 18mm wrench on sway bar links on the lower control arms. See Photo 46.

60. Depending on the brake caliper bolt size, the knuckle may need to be drilled. If the stock bolt is 16mm the caliper

mounting location may need to be enlarged using a 41/64” drill bit. On 2010 models, trial fit the stock caliper bolts to make sure the caliper needs to drilled before drilling. See Photo 47.

61. Remove the stock bearing assembly from the stock knuckle using a 18mm socket. Install the bearing assembly us-ing the stock hardware. Tighten using a 18mm socket. See Photo 48.

PHOTO 43 PHOTO 44

PHOTO 45 PHOTO 46

PHOTO 47 PHOTO 48

INSTALL THE SPACER TO THE STRUT INSTALL THE ASSEMBLY IN UPPER MOUNT

REINSTALL THE SWAYBAR ON CONTROL ARM REINSTALL THE SWAYBAR ON BRACKETS

INSTALL BEARING & HUB ON KNUCKLES DRILL KNUCKLE IF NEEDED FOR 16MM BOLTS

We recommend using OE instructions for disassembly and assembly of IWE actuator, the follow-ing instructions are for reference only.

62. Make sure the actuator splines line up to the splines on the CV shaft. See photo 49. 63. Install CV shaft into the knuckle assembly. See Photo 50. 64. Using a floor jack, raise the lower control arm and connect the upper ball joint on the upper control arm to the

spindle. Using a 21mm wrench, torque to manufacturer specs. If ball joint turns while tightening, use a 3/8”

wrench to hold the ball joint.

65. Reinstall the steering linkage nut using a 21mm wrench. 66. Using a hand vacuum pump, apply and hold 24inHG of vacuum to the actuator through the large port. See Pho-

tos 51 and 52.

67. Install the (3) bolts securing the actuator to the knuckle and tighten using an 8mm wrench. See Photo 53.

68. With vacuum still applied to actuator. Measure the depth of the CV shaft treads protruding through the hub bearing. If minimum 15.5mm or .61” is not achieved, rotate the hub to eliminate binding of the splines. See Photo 54.

Photo 49 Photo 50

Photo 51 Photo 52

Photo 53 Photo 54

69. Install the new knuckles using the stock hardware on the lower ball joints, making sure the half shafts are installed in the bearing assembly. Tighten using 24mm and a 12mm wrench. See Photo 55. Do not use air impact on the upper and lower ball joint, tighten with hand tools.

70. Install the half shaft axle nut and lightly tighten with HAND TOOL ONLY!! 71. Install the knuckle on the upper ball joint with the stock hardware and tighten using a 21mm and a 10mm wrench.

Do not use air impact on the upper and lower ball joint, tighten with hand tools.

72. Reinstall the locking hub vacuum hose as shown in Photo 57 on the hub mechanism and install the ABS wire on the bearing assembly using a 5mm allen wrench. See Photo 58. NOTE: The factory dust shield will not be reused.

73. Tighten the axle nut using a 13mm wrench and install the dust cap.

74. Install the rotor and caliper on the knuckle with the stock hardware using a 19mm or 21mm wrench. On 2010 mod-els with 16mm caliper hardware it will be necessary to use the qty 4, two per side 5/16” thick washers on the head of the caliper bolts. Failure to use these washers on the 16mm bolts will al-low the caliper bolt to protrude on the rotor side and can cause clearance issues. Tighten hardware.

See Photo 59. 75. Make sure the vacuum hose and ABS wire are out of harms way. Using the supplied zip tie, secure the vacuum

hose and ABS wire to the knuckle neck. 76. Install the tie rod end in the knuckle and tighten using a 21mm and 10mm wrench. See Photo 60. Do not use air

impact on the tie rod end, tighten with hand tools.

PHOTO 55 PHOTO 56

INSTALL KNUCKLE ON LOWER BALL JOINT

PHOTO 57 PHOTO 58

PHOTO 60

REINSTALL THE VACUUM LINE TO HUB REINSTALL THE ABS WIRE TO HUB

REINSTALL THE TIE ROD ON THE KNUCKLE

PHOTO 59

WASHERS WILL INSTALL HERE IF EQUIPPED WITH 16MM CALIPER BOLTS

REAR INSTALLATION

1. Chock the front tires and jack the rear the rear end up. Put jack stand under the frame rail and lower truck onto jack stands.

2. Remove tires and wheels using a 21mm socket. 3. Remove rear shocks from the upper and lower mount using 18mm and a 15mm wrench. See Photo 1 & 2. Retain

the stock hardware.

4. Using a 10mm wrench, remove the brake line assembly on the inner driver side frame rail. See Photo 3. 5. Install the brake line extension bracket on the frame using the stock hardware and tighten using a 10mm wrench.

See Photo 4. 6. Install the brake line assembly to the new bracket using the supplied 3/8” x 1” bolt, washers and nut. Tighten using a

9/16” socket and wrench. See Photo 4.

7. Separate the e-brake cable as shown on the drivers side and remove the e-brake cables from the frame mount as shown in Photo 5 & Photo 6.

PHOTO 1 PHOTO 2

PHOTO 3 PHOTO 4

PHOTO 5 PHOTO 6

REMOVE THE SHOCK FROM THE FRAME REMOVE THE SHOCK FROM THE AXLE

REMOVE THE BRAKE BRACKET FROM FRAME REINSTALL THE BRACKET TO NEW BRACKET

REMOVE E-BRAKE CABLE FROM BRACKET REMOVE E-BRAKE CABLE FROM FRAME

8. To install the new e-brake bracket measure from the rear measure 1 5/8” and from the bottom measure up 1 3/8” and mark hole to be drilled. See Photo 7 & 8.

9. Drill hole using a 11/32” drill bit. See Photo 9. 10. Install the new bracket as shown with the supplied 7/16” x 1” bolt, washers, nut in the factory hole and 5/16” x 3/4”

bolt, washer and nut in the drilled hole. See Photo 10. Tighten using a 19mm and 13mm socket / wrench.

11. Using a jack support the rear end and remove U-bolts using a 21mm socket and remove the factory blocks. Retain factory block for the 4” kit. See Photo 11.

12. Install the supplied blocks on the block pin holes on the axle and raise the axle into place. Taller end of the block to the rear. See Photo 12.

13. Install the axle u-bolts and tighten using a 22mm socket.

PHOTO 8 PHOTO 7

PHOTO 9 PHOTO 10

PHOTO 11 PHOTO 12

MEASURE 1 3/8” & MARK MEASURE 1 5/8” & MARK

DRILL USING 11/32” DRILL BIT INSTALL NEW BRACKET

REMOVE FACTORY U-BOLTS AND BLOCK INSTALL BLOCKS AND U-BOLTS

THANK YOU FOR CHOOSING ROUGH COUNTRY FOR YOUR SUSPENSION NEEDS

14. 6” Kits Only, Install the upper leaf spring u-bolts over the

leaf spring and into the blocks. Make sure to use the sup-plied block shims if needed to level the bottom surface of the leaf spring. Secure with supplied hardware and tighten using a 16mm socket. See Photo 13.

15. Install the new Rough Country shock absorbers in the upper and lower mounts using the stock hardware. Tighten using a

18 and 15mm wrench. If installing V2 rear shocks or Vertex rear shocks, refer to installation instructions included with those shocks.

16. Install the tire and wheels. 17. Raise up the rear of the vehicle and remove the jack stands.

Lower the vehicle to the ground. 18. Install the e-brake cable in the new mount and reattach the e

-brake cables on the frame. See Photo 14.

PHOTO 13

7/16”

9/16”

PHOTO 14

REINSTALL E-BRAKE CABLES TO BRACKET

CUTTING / DRILLING TEMPLATE—FR SIDE OF DRIVER CROSS-MEMBER

CU

T L

INE

CUTTING / DRILLING TEMPLATE—REAR OF DRIVER SIDE CROSS-MEMBER

CU

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INE

DR

ILL

POST INSTALLATION INSTRUCTIONS

1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and heated members. Check steering gear for interference and proper working order. Test brake system

2. Perform steering sweep. Check to ensure brake hoses have sufficient slack and will not contact rotating, mobile, or fixed members, adjust lines/brackets to eliminate interference and maintain proper working order. Failure to perform inspections may result in component failure

3. Readjust headlights to factory settings 4. Have vehicle aligned by a certified alignment professional. 5. Re-torque all nuts, bolts, and especially u-bolts after the first 100 miles, again after another 100 miles and then check

periodically thereafter 6. All components must be retightened after 500 miles, and every three thousand miles after installation.

Rough Country Accessories

Hidden Winch Plate #1010

By purchasing any item sold by Rough Country, LLC, the buyer expressly warrants that he/she is in compliance with all applicable , State, and Local laws and regulations regarding the purchase, ownership, and use of the item. It shall be the buyers responsibility to comply with all Federal, State and Local laws governing the sales of any items listed, illustrated or sold. The buyer expressly agrees to indemnify and hold harmless Rough Country, LLC for all claims resulting directly or indirectly from the purchase, ownership, or use of the items.